Search
Use the search bar or filters below to find any TAPPI product or publication.
Filters
Content Type
Publications
Level of Knowledge
Committees
Collections
Journal articles
A method to produce paperboard with a lightweight low-density coating, TAPPI Journal November 2025
ABSTRACT: In this work, a method is described in which a coating layer is produced that consists of a network of bubble-shaped air-filled voids within the coating. This is accomplished by instantaneously flash-drying all the water in the coating as it exits the application nip. The nip is formed between a polished chrome drum and a deformable press roll. The combination of the drum temperature, nip pressure, and nip width allow for sufficient energy to be transferred to the coating to completely flash-dry the coating material. The pressure within the nip is sufficient to allow the coating to superheat within the nip, then flash boil as it exits the nip. This boiling effect and resulting expansion are constrained by the roll surface, resulting in a coated surface that mirrors the polished chrome surface. The coating immobilizes while in the process of boiling, which preserves the bubble structure. With a coat weight of 5 g/m2, a flat, smooth surface is produced. This process was scaled up to a mill production machine layout and run at speeds as high as 450 m/min.
Journal articles
Magazine articles
Fundamental understanding of removal of liquid thin film trapped between fibers in the paper drying process: A microscopic approach, TAPPI Journal May 2020
ABSTRACT: In the fabrication of paper, a slurry with cellulose fibers and other matter is drained, pressed, and dried. The latter step requires considerable energy consumption. In the structure of wet paper, there are two different types of water: free water and bound water. Free water can be removed most effectively. However, removing bound water consumes a large portion of energy during the process. The focus of this paper is on the intermediate stage of the drying process, from free water toward bound water where the remaining free water is present on the surfaces of the fibers in the form of a liquid film. For simplicity, the drying process considered in this study corresponds to pure convective drying through the paper sheet. The physics of removing a thin liquid film trapped between fibers in the paper drying process is explored. The film is assumed to be incompressible, viscous, and subject to evaporation, thermocapillarity, and surface tension. By using a volume of fluid (VOF) model, the effect of the previously mentioned parameters on drying behavior of the thin film is investigated.
Journal articles
Effect of xylan on the mechanical performance of softwood kraft pulp 2D papers and 3D foams, TAPPI Journal March 2025
ABSTRACT: Pulp fibers are paramount in paper products and have lately seen emerging use in fiber foams. Xylan, an integral component in pulp fibers, is known to contribute to paper strength, but its effect on the strength of pulp fiber foams remains less explored. In this study, we investigate the role of xylan in both 2D handsheets and 3D foams. For a softwood kraft pulp, we enzymatically removed 1% from pulp fibers and added 3% xylan to them by adsorption, corresponding to approximately a decrease of a tenth and an increase of a third of the total xylan content. The mechanical properties of 2D fiber networks, i.e., handsheets, made using the xylan-enriched pulp improved, particularly regarding tensile strength and Young’s modulus; however, the decrease in mechanical properties of handsheets made from enzymatically- treated xylan-depleted pulp was more pronounced. In 3D networks • pulp fiber foams, much less fiber-fiber contacts formed, and thus the mechanical properties were not as much influenced by removal of xylan. Furthermore, the presence of the required surfactant on the fibers, acting as debonding agent, overshadows any positive effect xylan might have on fiber-fiber bonding. We propose that the improved mechanical properties for the sheets result from a combination of an increased number of fiber-fiber bonds and higher sheet density, while the deterioration in mechanical properties of handsheets comprising enzymatically-treated fibers is caused by the opposite effect.
Journal articles
Magazine articles
Predicting strength characteristics of paper in real time using process parameters, TAPPI Journal March 2022
ABSTRACT: Online paper strength testing methods are currently unavailable, and papermakers have to wait for manufacture of a complete reel to assess quality. The current methodology is to test a very small sample of data (less than 0.005%) of the reel to confirm that the paper meets the specifications. This paper attempts to predict paper properties on a running paper machine so that papermakers can see the test values predicted in real time while changing various process parameters. This study was conducted at a recycled containerboard mill in Chicago using the multivariate analysis method. The program provided by Braincube was used to identify all parameters that affect strength characteristics. Nearly 1600 parameters were analyzed using a regression model to identify the major parameters that can help to predict sheet strength characteristics. The coefficients from the regression model were used with real-time data to predict sheet strength characteristics. Comparing the prediction with test results showed good correlation (95% in some cases). The process parameters identified related well to the papermaking process, thereby validating the model. If this method is used, it may be possible to predict various elastic moduli (E11, E12, E22, etc.) in the future as the next step, rather than the traditional single number “strength” tests used in the containerboard industry, such as ring crush test (RCT), corrugating medium test (CMT), and short-span compression strength test.
Journal articles
Magazine articles
Effects of phosphogypsum whiskers modification with calcium stearate and their impacts on properties of bleached softwood paper sheets, TAPPI Journal September 2021
ABSTRACT: By combining the structural properties and characteristics of phosphogypsum whiskers, a preliminary study on the modification of phosphogypsum whiskers and their application in papermaking was carried out. The effects of reaction temperature, reaction time, and reaction concentration on the solubility and retention of modified phosphogypsum whiskers and the effects of phosphogypsum whiskers on the physical properties of paper under different modified conditions were explored. The research results show that, after the phosphogypsum whiskers are modified with calcium stearate, a coating layer will be formed on the surface of the whiskers, which effectively reduces the solubility of the phosphogypsum whiskers. The best modification conditions are: the amount of calcium stearate relative to the absolute dry mass of the phosphogypsum whisker is 2.00%; the modification time is 30 min, and the modification temperature is 60°C. The use of modified phosphogypsum whiskers for paper filling will slightly reduce the whiteness, folding resistance, burst resistance, and tensile strength of the paper, but the tearing degree and retention of the filler will be increased to some extent.
Journal articles
Magazine articles
Rheological characteristics of platy kaolin, TAPPI JOURNAL September 2019
ABSTRACT: Platy kaolin can provide significant value in the coating of paper and paperboard. It can be used in multiple applications and can provide benefits such as titanium dioxide (TiO2) extension, smoothness improvement, improved print gloss or ink set rates, calendering intensity reduction, and improved barrier properties. It is not a pigment that can be simply substituted for traditional hydrous kaolin without some adjustment to the coating formulation. These adjustments can be as simple as reducing solids, but may require binder changes as well. The coater setup may need to be adjusted because of the unique rheological behaviors these pigments exhibit.The unique rheological characteristics of platy kaolin are explored here. Measurements of the water retention of platy kaolin containing coatings confirm that water retention is not reduced in comparison to more blocky kaolin pigments, despite the lower coating solids at which they need to be run. This means that the rheological characteristics are the most important in understanding the runnability. An extensive analysis reveals some unique behaviors that need to be understood when utilizing these materials. Viscoelastic measurements indicate that, for this binder system, Tan d is mainly a function of solids. This may explain how weeping is initiated on a blade coater. The degree of shear thinning behaviors is investigated using the Ostwald de-Waele power law. The immobilization point was determined using the Dougherty-Krieger equation and related to the work of Weeks at the University of Maine on blade coater runnability. An indirect measure of particle shape and size synergy is also demonstrated using the Dougherty-Krieger equation parameters.
Journal articles
Magazine articles
Key material properties in crease cracking of kraft paper, TAPPI Journal February 2021
ABSTRACT: Crease cracking of paperboard is important to control for the appearance and structural integrity of packages. Crease cracking is affected by creasing operation variables, as well as the physical properties of the paperboard. However, the effects of the physical properties are not clearly known. The objectives of this work were to identify the key material properties that affect crease cracking and to clarify the effects of fiber composition and starch. Laboratory sheets were produced from bleached and refined softwood and hardwood commercial pulp at grammage and thicknesses that match a typical paperboard. To mimic papermaking operations, surface starch was applied via a bench-top size press. The sheets were creased in the lab over a range of penetration depths, and reverse-side cracking was measured. The results showed that less reverse-side cracking was correlated with higher tensile post-peak energy, a lower bending stress, and a lower z-direction (ZD) stiffness. The tensile post-peak energy is a measure of the resistance to crack growth via fiber-bridging. The bending force and the ZD stiffness influence the forces that create cracks. It was observed that decreasing the ratio of hard-wood-to-softwood content and reducing the amount of starch would both decrease crease cracking.
Journal articles
Magazine articles
Application of foamed additives to the surface of wet handsheets, TAPPI Journal January 2021
ABSTRACT: We explored the application of foamed wet-end additives onto wet handsheets to qualify our method of application and to demonstrate the method’s usefulness for prescreening additives and foaming agents for packaging applications.We modified a laboratory drawdown coating machine to allow coating of wet handsheets with foamed additives. Initial sheet solids were adjusted to a target of 8%•25% by vacuum. Foam layer thickness was set mechanically. After application, the foamed additives were drawn into the sheet with vacuum. The additive dosage was adjusted by altering its concentration within the foaming formulation. We evaluated more than 100 foaming agents and 10 strength additives, comparing wet-end and foam-assisted addition with no addition on recycled linerboard and virgin linerboard furnish. Foam-assisted addition typically displayed a much steeper dose-response curve and much higher maximum strength levels than wet-end addition. Our results suggest potential target applications for this technology, such as lightweighting, and improved strength performance in mills with relatively closed water systems, where strength aids added into the wet end are adversely influenced by accumulation of inorganic ions and organic species.
Journal articles
Magazine articles
The effect of contact time between CPAM and colloidal silica on the flocculation behavior in the approach flow, TAPPI Journal January 2021
ABSTRACT: Multicomponent wet-end systems have become increasingly common in papermaking, with the objective of improving the retention-formation-dewatering relationship. It is quite common to use at least a cationic polymer, often in combination with an anionic microparticle. In some cases, a fixative is also used. However, there is still debate on the optimal implementation of these systems. In particular, optimizing the contact time of the cationic polymer prior to addition of the anionic microparticle is still poorly understood. In this work, we investigate the effect of the contact time of a cationic polyacrylamide (CPAM) prior to addition of colloidal silica on the flocculation response in a flowing fiber suspension. The effect of using a fixative is also investigated. Focused beam reflectance measurements (FBRM) are combined with zeta-potential measurements for optimizing the addition levels of a two- and three-component system, as well as for elucidating the effect of contact time on CPAM performance. Trials are then performed on a pilot scale flow loop, where the time between addition of these two components is varied and the resulting flocculation response is characterized using high-speed filming and image analysis techniques. It is shown that the efficacy of CPAM can be improved through use of a fixative and that a longer CPAM contact time may be beneficial in terms of immediate flocculation; however, hydrodynamic shear tends to dominate the flocculation response regardless of contact time due to floc rupture.
Journal articles
Water-based adhesive penetration into paperboard and coated paperboard, TAPPI Journal January 2025
The setting of water-based adhesives in contact with paperboard is important in the production of boxes and other packaging, but the topic has received little attention in the literature. The penetration of the adhesive into the paper surface is important to get good bond strength through mechanical interlocking. The influence of the process conditions and the paper properties on this penetration is lacking. A water-based adhesive was applied to an uncoated and coated paperboard. The coating layer had two latex levels. Samples were characterized in terms of air permeability, void fraction, average pore size, and coat weight. The adhesive was applied to the samples in a mechanical press, squeezing a drop between two samples. The penetration of the adhesive was characterized with a silicone oil absorption method that measured the decrease in pore volume after the adhesive had been applied to approximate the pore volume taken up by the adhesive. The bond strength was measured with a peeling test. The penetration depth into uncoated paper did not depend on the application method parameters such as pressing time, pressure, or initial solids of the adhesive. The penetration depth ranged from 35•40 mm. The penetration into 10 pph latex content coated paper was similar to the uncoated samples, but reduced penetration was observed into the 40 pph latex content coatings. The results were compared to the limiting amount of adhesive that was obtained from the weight gain of the samples and to a simple model that is based on flow in porous media. Peel tests revealed that good penetration was needed, as well as a strong coating layer to obtain high peel forces.